Content

Introduction, environmental concerns and recommendations, event data recorder, customer assistance center, reporting safety defects

Vehicle identification

• Vehicle specification decal
• Federal motor vehicle safety standard (FMVSS) labels
• Canadian motor vehicle safety standard (CMVSS) labels
• Tire and rim labels
• EPA emission control

Vehicle access and features

• Cab door locks and handles
• Door windows
• Cab entry and exit
• Seats
• Seat belts and tether belts
• Seat belt operation
• Fuse / relay / circuit breaker identification
• Cab tilting
• Front access panel
• Back-of-cab grab handle, step, and deck plate

Driver controls and instruments

• Instrument and control panel
• Controls
• Warning and indicator lights
• Instruments
• Heater and ventilation system

Engines

• Engine starting
• Cold start manifold heater
• Cold weather operation
• Engine break-in
• Engine operation
• Engine shutdown
• High altitude operation
• Engine braking system, optional

Transmissions

• Fuller straight-shift models
• Allison automatic transmissions

Clutches, rear axles, and steering

• Clutches
• Rear axles
• Steering system

Brakes

• Air brake system

Cab appearance

• Cab washing and polishing
• Care of chromed parts and stainless-steel clad parts
• Dashboard care
• Vinyl upholstery cleaning
• Cloth upholstery cleaning

Pretrip inspection and daily maintenance

• Pretrip inspection checklist
• Pretrip inspection and daily maintenance procedures

In an emergency

• Hazard warning lights
• Towing
• Emergency starting with jumper cables
• Fire in the cab

Fifth wheels

• Holland fifth wheels
• Fontainefifth wheels

Maintenance manual contents

General information

• Determining scheduled maintenance intervals
• Initial maintenance (IM) operations
• Lubrication and fluid level check
• Maintenance interval operations table
• Maintenance operation sets table
• Maintenance service table
• Metric / U.S. customary conversion tables
• Noise emission controls maintenance
• Torque specifications tables
• Verification of inspections log

Engine

• Engine drive belt inspection
• Engine-support fasteners check

Air intake

• Air cleaner element inspecting and replacing

Air compressor

• Air compressor inspection, holset

Alternators and starters

• Alternator and starter check

Engine cooling / radiator

• Radiator cap check
• Radiator pressure flush and coolant change

Clutch

• Clutch inspection and adjustment
• Clutch master cylinder fluid level check
• Clutch release bearing and release cross-shaft lubrication

Transmission

• Allison transmission fluid and filter change
• Allison and Eaton/fuller transmission breather check
• Eaton/fuller transmission air filter/regulator element clean
• Manual transmission oil change and magnetic plug clean
• Manual transmission oil level check

Frame and frame components

• Fifth wheel inspecting
• Fifth wheel lubricating
• Frame fastener torque checking

Suspension

• Suspension inspecting
• Suspension lubricating
• Suspension u-bolt torque checking

Front axle

• All-axle alignment checking
• Knuckle pin lubricating
• Tie-Rod End Inspection
• Tie-Rod End Lubrication

Rear axle

• Axle breather check
• Axle lubricant change and magnetic plug clean
• Axle lubricant level check

Wheels and tires

• Wheel nut and rim nut check

Driveline

• Driveline inspecting
• Driveline lubricating

Brakes

• Air brake valve disassembly, clean, and inspection, Bendix E–6, QR–1, and ST–3
• Air brake valve operation check
• Air dryer check, Bendix AD–9
• Air dryer desiccant replacement, Bendix AD–9
• Air dryer inspection, Bendix AD–9
• Air reservoir automatic drain valve disassembly, clean, inspection, and Lubrication, Bendix AD–9
• Automatic slack adjuster check
• Automatic slack adjuster inspection
• Automatic slack adjuster lubrication
• Brake chamber inspection (all models)
• Camshaft bracket bushing lubrication
• Foot brake valve actuator lubrication
• Quick release and flipper valves check
• Relay valve check

Steering

• Drag link lubrication
• Power steering reservoir fluid level check
• Power steering reservoir fluid and filter change
• Steering driveline lubrication
• Steering gear lubrication

Fuel

• Fuel tank drain and vent check

Exhaust

• Exhaust system inspecting (noise emission control)

Electrical, instruments, and controls

• Battery, battery box, and cable check and clean
• Electrical system check
• Ground cables check and clean

Cab

• Cab mounting bolts torque check
• Cab mounts lubrication
• Cab roof vent lubrication

Doors

• Weatherstrip, door latch, and door hinge lubrication

Heater and air conditioner

• Air conditioner check, R–134A refrigerant systems
• Air filter replacement